Copolymers of vinylidene cyanide with vinyl chloride



Patented Oct. 28, 1952 COPOLYMERS OFVINYLIDENE CYANIDE WITH VINYL CHLORIDE Vernon L. Folt, Akron, Ohio, assignor to The B. F.

Goodrich Company, New York, N. Y., a corporation of New York No Drawing. Application February 14, 1950, Serial No. 144,196

3 Claims.

This invention relates to the preparation of novel copolymers of vinylidene cyanide with vinyl chloride, which copolymers are extremely useful synthetic resins especially in the preparation of filaments and films. p

In U. S. Patent 2,476,270 to Alan E. Ardis, and in copending applications, Serial No. 63,434, filed December 3, 1948, now U. S. Patent 2,502,412, and Serial No. 79,712, filed March 4, 1949, now U. S. Patent 2,514,387, novel methods for the preparation of monomeric vinylidene cyanide are disclosed. These methods involve, respectively, the pyrolysis at 400 C. to 750 C. of 1-acetoxy-1,1- dicyano ethane, the pyrolysis of 1,1,3,3-tetracyanopropane and the pyrolysis at 400 C. to 800 C. of 4,4-dicyanocyclohexene, 4,4-dicarbamyl cyclohexene or 4-cyano-4-carbamy1 cyclohexene. In another copending application, Serial No. 11,336, filed February 26, 1948, methods for the preparation of useful ho-mopolymers of vinyliclene cyanide are disclosed.

Monomeric vinylidene cyanide is a clear liquid at room temperature and a crystalline solid at C. It melts in the range of 6.0 C. to 9.7" 0., depending on purity, with purest samples melting at 90 C. to 97 0., and it boils at 40 C. at a reduced pressure of 5 mm. of mercury. It is quite unstable becauseof its extreme sensitivity to water, undergoing on contact with water at room temperature an instantaneous homopolymerization reaction to give a solid, waterinsoluble resin. When it is allowed to stand at room temperature in admixture with butadiene- 1,3 it reacts therewith to give solid 4,4-dicyanocyclohexene.

It has now been discovered that when monomeric vinylidene cyanide of the above physical and chemical characteristics is copolymerized with vinyl chloride, in the presence of a free radical polymerization catalyst and in a manner such that the polymerization charge contains from 5 to 45 mole per cent of monomeric vinylidene cyanide new and highly useful copolymers are obtained. These copolymers are essentially 1:1 alternating copolymers, that is, copolymers possessing the structure:

M1M2 M,-M. .M1M. wherein each M1 is a vinylidene cyanide unit H ON each M2 is a unit of vinyl chloride and a: is a poly digit number, preferably from 100 to 15,000.

The fact that the copolymers thus obtained are essentially 1:1 alternating copolymers is determined by analysis of the copolymer for nitrogen and/or chlorine content-which shows that the two monomers enter the polymer chain in essentially equimolar ratios regardless of the degree of monomer to polymer conversion and of charging-ratio provided the latter is within the range of 5 to 45 mole per cent vinylidene cyanide. Further supporting evidence for this fact is found in the copolymerization equation of F. M. Lewis, C. Walling, et al., Journal of the American Chemical Society, 70, 1519 (1948):

wherein M1=Concentration of unreacted monomer M1 M2=Concentration of unreacted monomer M2 T1=Rati0 of the rate constants for the reaction of an M1 type radical with M1 and M2 respectively r2=Ratio of the rate constants for the reaction of an M2 type radical with M2 and M1 respectively When the product of T1 and re (the values of T1 and 12 being determined by solving'the equation for n and m) is equivalent to zero, a 1:1 alternating copolymer is formed, that is, a copolymer having the structure shown hereinabove. When M1 is vinylidene cyanide, and M2 is vinyl chloride it has been found that r1=0.72 and rz=0.0093; therefore, the product of n and T2 is 0.0071, or approaches zero, so that the equation indicates that essentially alternating copolymers are formed.

The polymerization of this invention can be carried out in a number of ways. vSince the monomers are mutually soluble in one another, the polyberization may be carried out without the use of a solvent or other liquid medium for the monomers simply by mixing the two monomers with the catalyst, and then heating the resulting mixture to a temperature of from about 30 C. to 0., and preferably about 50 0., whereupon polymerization occurs to form the demerizer is then sealed to the air-and broughtto the desired polymerization temperature, preferably with constant agitation of the polymerization:

mixture. When the desired degree of conversion has occurred, the mixture is cooled to about '70 C. to stop the polymerization, the polymerizer is opened and thacopolymer is separated from the polymerization mixture in the manner described in the foregoing paragraph. If desired, benzene or other aromatic hydrocarbons may be introduced into the polymerizeratogether with the catalyst, thus facilitating recoveryof the. copolymer, since the monomersremaining after the polymerization is" stopped will be. in-solutioninthe aromatic hydrocarbon-and the copolymer can-be-readily recovered simply by passing: the contents. of the polymerizer through a.

suitable filter.

Theuseof. polymerization temperatures in the range 0130 to-80" C. is preferred but not at all criticalsince polymerization will, occur at temperaturesaslow as C. or ashigh as .100" C.

It is to be understood that. regardless of the polymerization method-utilized, the polymerize-- tion should be stoppedbefore monomeric vinylidene cyanide is entirely consumed; in order that substantially pure copolymer will be obtained. Otherwise, when the vinylidene cyanide is com.- pletely used up, theproductwill contain straight polymer resulting from the poymerization of. the remainingvinyl chloride. Accordingly, it is often. desirable to add, coninuously or intermittently, fresh quantities of vinylidene cyanide, and also-of catalyst and solvent if, desired, to the polymerization mixture during the course of the polymerization, thus taking fullest advantage of the capacity of the equipment and in efiect operating acontinuous or semi-continuous process.

The catalyst which isutilized in. the polymerization process is preferably aperoxygencompound such as silver peroxide, the perborates, the percarbonates, benzoyl peroxide, caproylperoxide, lauroyl'peroxide, acetone-peroxide, acetyl benzoyl peroxide, cumene hydroperoxide, o,o'dichlorobenzoyl: peroxide, o,o--dibromobenzoyl peroxide,,caprylylperoxide, pelargonyl peroxide, tar-'- tiary butyl hydroperoxide, and the like. In general, from 0.01 to 2.0% by weight (based on the total weight of'the' monomers charged) of, the catalyst is utilized, although smaller" or larger amounts .maybeutilized-if desired; By regulating the amount of the catalyst employed'it is possible to control very effectively and accuratelythe.

molecular weight of the copolymer. For; in'-. stance, to obtain aliigh molecular weightcopoly mer, a small'quantity of catalystj is used, while lower molecular weight. copolymersnare obtained;

by the use of larger amounts of catalyst;

The rate of" copolymerization .canalso -be, controlled by regulating the catalyst concentration.

A vacuum' 4 It has been determined that the copolymerizatioh rate is proportional to the square root of the catalyst concentration, and accordingly, the rate of copolymerization increases when the catalyst concentrationv increases, the, converse also being true.

The following examples illustrate the preparation of copolymers of vinylidene cyanide with vinyl chloride in accordance with this invention, butgarejnot, to be construed as a limitation upon thescopathereof, for there are, of course, numerous possible variations and modifications.

Examples I to VIII A series of vinylidene cyanide :vinyl chloride copolymers, are prepared from charges containing mole percentages of vinylidene cyanide varying from approximately 5 to 45. In the procedure utilized, 0.30% by weight (based on the total weight of monomers to be charged) of o,o'dibromobenzoyl peroxide is placed in apolymerizer; thepolymerizer is then evacuated and-immersed in a Dry-Ice/acetone bath and the vinyl chloride" introduced into the evacuated polymerizer: Thevacuum is then broken and the vinylidene cyanideadded.- The polymerizer is thensealed, hea-ted'to'a temperature of'about 50C. andagitatedconstantly. After periods of time varying from-4.5 to l6'hours the polymerization is stopped by'cooling the polymerizer to a temperature of about-70 C'. Benzene is addedto the:contents of the polymerizer' and the resultant benzene slurry is filtered to give a high molecular weight: resinous copolymer, of vinylidene cyanide with vinyl, chloride. In: the table below there are: recorded the mole per cent vinylidene cyanide-in the; charge, the timeduring which the polymerization is permitted to continue. the per cent monomer to-polymerconversion (based on total weight of monomers present) and the mole. per cent vinylidene cyanide in theresultingcopolw mer= ('based'on nitrogen analysis) I MolePer Polymeriza- Percent cent Vinyli- Example Cyanide Time Conversion delle Charged ours) amde 111 Copolymcr 4; 04 8. 0 2. 0 44. 00 S. 17' 8. 0 4. 0 48. 38 12x38 8. 0 to 16. 5 2 2.0-to10. 0 49.47 16168 '8. (H0 16'. 5 0 014. 0 50165 21.06 8.0110 16.5 2 2.0120204 51.15. 25. 54.- 1 81 0 vto 16. 5 2 2. 0 to 24. 0 52.120, 34. 8.,0t0 16; 5 2.0 to 2470' 55. S4, VIII-.14-- 44. 46' 8.0, to 16. 5 5 2. 0 L0 25. 0- 59. 70

1 Several rnnscerried out; at, polymerization times within this rengcw utilizing the same chargingv ratios.

2 ocvcral'runs carried out using identical monomer mixtures polymcrizedltn vanouaconvcrsions within tliisranga.

vItwill be seen from theab'ove, examples that an, essentially 111 alternating copolymer is. ob:- tained whenthe polymerization charge contains. from 5.to 45. mole per cent of vinylidene. cyan mus- When the polymerization is carriedeout.

according to other or the methods described hereinabove, or at temperatureshigher or. lower than 1 about 50 C., or utilizing other of the peroxygen catalysts herein disclosed, the essentially 1:1 alternating copolymer is again readily obtained.

The copol-ymers of vinylidene cyanide with vinyl chloride prepared according to this invention are useful in the preparation of solutions from which can be spun fibers and filaments of any desired size. Such synthetic fibers and filaments possess many, advantageous-properties including extremely high strength, low elongation,

excellent resistance to weathering and excellent resistance to the action of chemicals. The copolymers, and fibers and filaments thereof, are not degraded, even after being soaked in a sodium hydroxide solution for in excess of 24 hours.

To illustrate the preparation of fibers and filaments, the copolymers obtained in the above examples are dissolved in dimethyl formamide to give viscous, stable solutions which are spun through a spinneret into a spinning bath to give excellent filaments. The physical properties of these filaments are excellent and can be even further improved by a hot-stretching process, whereby the filament is stretched in a hot zone in a series of steps, a process disclosed in a copending application, Serial No. 113,018, filed August 29, 1949. In addition to dimethyl formamide, other solvents for the copolymers may also advantageously be used, and the copolymer solutions are also useful for the casting of valuable films. Moreover, since the vinylidene cyanide-vinyl chloride copolymers of this invention. have a very high but definite softening point (above 200 C.) they are useful in melt spinning and in the preparation of molded objects for use in applications where thermal stability is essential.

Although specific examples of the invention have been herein described, it is not intended to limit the invention solely thereto, but to include all of the variations and modifications falling within the spirit and scope of the appended claims.

I claim:

1. A copolymer of vinylidene cyanide and vinyl chloride, said copolymer possessing essentially the wherein each M1 represents a vinylidene cyanide unit, each M2 represents a unit of said vinyl chloride and :c is a polydigit number, in which copolymer the vinylidene cyanide units are derived from monomeric vinylidene cyanide which is a liquid at room temperature and a crystalline solid at 0., having a melting point, when in purest form, of substantially 9.0 C. to 9.7 C., and being characterizable chemically by the ability to undergo on contact with water at room temperature an instantaneous homopolymerization reaction to give a solid, water-insoluble resin.

2. The method which comprises introducing vinyl chloride into a closed vessel containing a peroxygen catalyst and being maintained at a reduced pressure and at a temperature below about 0 C., allowing the pressure in said vessel to rise to substantially atmospheric pressure, and introducing vinylidene cyanide into said vessel, the said vinylidene cyanide being present in an amount from 5 to mole per cent based on the total monomer weight and being a liquid at room temperatur and a crystalline solid at 0 C. having a melting point, when in purest form, of substantially 9.0 C. to 937 C. and being characterizable chemically by the ability to undergo on contact with water at room temperature an instantaneous homopolymerization reaction to give a solid water-insoluble resin, and maintaining the resulting mixture at a temperature of from 30 C. to C. for a time sufiicient to effect copolymerization of the said vinylidene cyanide and vinyl chloride and formation of a solid, resinous copolymer possessing the structure M1M2 1Mz =M1M2 wherein each M1 is a vinylidene cyanide unit, each M2 is a vinyl chloride unit and a: is a polydigit number.

3. The method of claim 2 wherein the peroxygen catalyst is o,o'-dibromobenzoyl peroxide.

VERNON L. FOLT.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,455,653 Bralley Dec. 7, 1948 2,462,422 Plambeck Feb. 22, 1949 2,466,395 Dickey Apr. 5, 1949 

1. A COPOLYMER OF VINYLIDENE CYANIDE AND VINYL CHLORIDE, SAID COPOLYMER POSSESSING ESSENTIALLY THE STRUCTURE 